Copolymers of unsaturated alkyd resins and acrylamido compounds



Patented June 3, 1952 COPOLYIHERS F UNSATURATED ALKYD RESINS AND ACRYLAMIDO COMPOUNDS Edward L. Kropa, Old Greenwich, Conn., assignor to American Cyanamid Company, New York, N. Y., a corporation of Maine No Drawing.

Original application October 31,

1946, Serial No. 707,043. Divided and this application April 21, 1948, Serial No. 22,494

14 Claims.

. This invention relates to polymerizable compositions, to the polymerization of such compositions to form insoluble resins, and to the production of coating compositions, molding compositions, molded articles, laminated articles, etc., from the polymerizable compositions. Polymerizable compositions of this invention include a reactive alkyd resin and an organic substance, generally a reactive solvent. Upon reaction of these substances, a substantially insoluble resin is formed.

One of the objects of this invention is to prepare improved resins and especially to obtain clear and colorless gels.

It is also an object of this invention to provide potentially polymerizable solutions which would be stable during storage.

Still another object of this invention is to control the rate of polymerization of the reactive mixture, as well as to improve the properties and characteristics of resulting gels.

Another object of this invention is to prepare compounds particularly suitable for use as coating compositions and as components in coating compositions.

A further object of the present invention is to prepare molding compositions and especially to prepare clear and colorless molded materials.

Another object of this invention is to prepare laminated moldings having high strength and other desirable properties.

A still further object of this invention is to provide molding compositions suitable for injection molding. Other objects will be apparent from the description.

According to the present invention, I have found that substantially insoluble, substantially infusible resins may be prepared by means of the chemical reaction or polymerization of a mixture containing a resin possessing a plurality of polymerizably reactive alpha, beta-enal groups, 1. e.

c= ;-b=o and an organic substance which contains an amido group \NC- II a polymerizably reactive CH2:C group, and no conjugated carbon-to-carbon double bonds. Such'mixtures may be utilized in coating compositions, in molding compositions, in laminating, in adhesives, in casting compositions, etc.

For the sake of brevity, the organic substances which contain the amido group and the polyand they are thus to be distinguished from the resins which possess a plurality of polymerizably reactive alpha, beta-enal groups andwhich will be designated herein as "reactive resins or as: unsaturated alkyd resins. I

Among the reactive resins used in the practice of this invention for interaction with reactivematerials containing CI-Iz:C groups arelthose which are derived from alpha, beta-unsaturated organic acids and, therefore, contain the reactive groupings present in these acids. The term acids as used herein is intended to include the anhydrides as Well as the acids themselves, since the former may be used instead of the acid. ,The term alpha, beta-unsaturated organic acid as used in the art does not include acids wherein the unsaturated group is part of an aromatic-acting radical as, for example, phthalic acid, and the same definition is adopted herein.

Resins used in the practice of the present invention are preferably produced by the esterification of an alpha, beta-unsaturated polycarboxylic acid with a polyhydric alcohol, particularly a glycol. Although esterification of the acid witha polyhydric alcohol is perhaps one of the simplest, most convenient ways of obtaining a reactive resin, I am not precluded from using resins otherwise derived from alpha, beta-unsaturated organic acids- Reactive resins suitable for my in vention are any of those containing a plurality of polymerizably reactive alpha, beta-enal groups. A reactive resin such as one prepared by esterification of an alpha, beta-unsaturated organic acid and a glycol or other polyhydric alcohol is mixed with a reactive material containing the CH2:C group. Upon adding a polymerization catalyst and subjecting the mixture to polymerization conditions such as, for example, heat, light, or a combination of both, a substantially insoluble, substantially infusible resin is obtained.

The invention will be described in greater detail in conjunction with the following specificexamples in which the proportions are given in parts by weight. It should be understood that the examples are merely illustrative, and it is not intended that the scope of the invention, be

" limited to the details therein set forth.

Example 1 u methylene "bis-acrylamide o vigorous reaction 7 occurs, accompanied "evolution oif gas. Asthe mass poiymer'izesand 1 sets; it*in'rd'er'goes about-a twofold expansion and.

acid condensation of two moles of acrylamide with one mole of iormaldehyde as described and claimed in the copending application of Lennart j A. LundbergSerial No, 707,040 filed October. 31,

V absence prepared by strong 3 1 1946 nowzPatnt No.'2, 47.5,846 dated July 12, 1949; V

To 12 partsof the mixture prepared above are added 8 parts of wood flour filler and 2 parts of' j benzoyl peroxide containing 50% inactive ,filler j (triphenyl phosphate). The resulting mixture is g compacted by passage through cold rolls and dis- 1 integrated and this composition is then placed j in a disk mold preheated to 160 and left there 1 under pressure for about 15 minutes.

The resulting molding is hard and well-cured.

A pulverized mixture of parts of ethylene glyeol'fumarate sebacate (4:3:1 molar ratio), 1-0 1 parts of methylene'bis-a'crylamide, and 0.3 part 1 .01; benzoyl peroxide is spread evenly between 51 plyiof. ECCe=11-112 Fiberglas' cloth and the com 3 binationheld under slight pressurevin a. Carver 1 press: for: about minutes at about '160- C.

l Where the. Fiberglas cloth is well impregnated,

, i the resin becomes hard and brittleandthe'panel.

stilt; thelatter having Barcol readings averaging- Example 3v 7 v frhjeresin mixture of Example 2' is spread, evenlfyi tween'fiply of #720 paper and the combinaubject'ed to the same curing conditionsa's 1 thef'iberglas'laminate of Example 2; The'resjult- V e ifig fianelis stiff with a Barcol hardness of 35. 7 V

. p 7 Example-4 repeated'using in place of the ethylene bis acrylamide,methylene bis m'eth V i arylamide'preparedby strong acid condensation 1 of two moles of methacryl'amidewith one mole of-formaldehyde asxdescribedandclaimed inthe v 71 depending application of'liennart'AgLundberg,

' 1 Serial No.' 707 ,"O iO filed'O-ctober 31, 194'6 now Pat- A nt-No;2,;4'75;s4s dated July 12, 1949: The resultingmold ngsis' uniformly well-cured; or '7 Eafampled mampi f-z is repea-ted-using inethylene"bis-' 1 xia'iethacrylainide in place of methylene bis-acrylam The resulting'Fibergla's. laminate possess: es high modulus in bending'and' is "found' to 1 hveaBarcolhardness averaging 51.

Example 6 Escapist isrep eated using me thyl'ene h s i methaor ylamide in place of methylene bis' fitlylf' amiue- The" resulting paper laminate is well;

1 bonded ands-ass V Examplei 1 phenyl h h e a e th il 'l'rf j i sz a suitable vessel and then heated at the cured massisfporous."

Eachipled 1170270 sea diethylene glyco ruma rate I c'at' Barcol-hardness of' about 45-50.- 5

is l'partsof diethylene glycolfuinaratesehaoate 6 7 (6 15' LlilOl-af Tafib), '33 parts 0f :aerylaimidy 7' i tio'n are characterized acrylamide containing 0.3 part of benzoyl peroxide dissolved therein are added. The mixture is not compatible at room temperature.

The dispersion is cast as a flat sheet in a glass c'elljand cured for '2 hours at'fiflf C. and then 2 1 hoursat C.

The resulting cured resinrsheet is clear and light-colored, and has a Barcol hardness of about a tion'with a reactive resin according tomy'invenby the presence of the and the polymerizably reactive CH=C group, and none of them contains conjugated carbonto-carbon double bonds. They may be represented by one or the other of the following general formulaez' '7 and e l 1 xu r-o-mll in which R; may be an. unsaturated aliphatic radical containing .at least one CH2 =C group and. no conjugated carbon-to carbon' double bonds, B. may be the sameas. R1 orit'may'befan unsaturated oxyaliphatic radical containing. .at.

- least one CH2=C group andno conjugated V carbon-tocarbon double bonds, Rz,.Ra, anam' may be hydrogen or alkyl, alk-ylol, aryl} or aralkyl radicals and X is an alkylidene radical. Still more particularly the reactive materials "(that is.

reactive" acrylamido. compounds) that are'employed in practicingthe invention herein claimed,

are monomeric, substances; which Tare compatible and copolymerizable with the reactive resinithat is, a polymerizab le unsaturated alkyd resin con taining a plurality of polymerizably reactive alphabetaenal groups) I and which are selected from the group consisting of compounds having 7' thefollowinggeneral formulae; 7

and

in which Y is a member oi the group consisting of hydrogen and alkyl radicalso'f 1 to 2' carbon c atoms, R1 is selected iromthe group consisting of hydrogen and alkyl; alkylol; aryl and aralkyl radicals, R2 is selected :from thegroup vconsisting of alkyl, alkylol, aryl and aralkyl radicals,-Ra,is

selected fromthe group consisting of hydrogen and alkyl, aryl andaralkyl'radicals, and X is an 7 alkylidene radical.

Compounds containing a conjugated system of e sesame-ragga Allof the reactive materialssuitable for-mac e Dims-nicer re'ae the present invention which contain no conjugated carbon-to-carbon double bonds obviously cannot undergo this type of reaction with the maleic esters. Accordingly, my invention is not directed to the use of unsaturated compounds containing conjugated systems of carbon-to-carbon double bonds. Many substances which contain a carbon-to-carbon double bond conjugated with respect to oxygen are suitable for use according to my invention since they do not react with unsaturated alkyd resins in an undesirable manner but, instead, copolymerize or interpolymerize to form substantially infusible, substantially insoluble resins.

Among the reactive materials which may be used in the present invention are esters of the lower unsaturated aliphatic alcohols such as allyl alcohol, its homologues, for example methallyl alcohol, its substitution products, for example chlorallyl alcohol, with carbamic acid, and monoor di-N-substituted carbamic acids in which the substituent or substituents on the nitrogen atom may be alkyl, for example N-methyl carbamic acid, N-ethyl carbamic acid, N,N-dimethyl carbamic acid, etc., alkylol, for example, N-methylol carbamic acid, etc., aryl, for example N-phenyl carbamic acid, N,N-ditolyl carbamic acid, etc., or aralkyl, for example N-benzyl carbamic acid, N ,N- dibenzyl carbamic acid, etc. Mixed acids such as N-ethyl-N-phenyl carbamic acid, N-phenyl-N- benzyl carbamic acid, and N-methyl-N-benzyl carbamic acid may also be esterified with an unsaturated aliphatic alcohol and the ester copolymerized with unsaturated alkyd resins according to the present invention. Copolymers of unsaturated alkyd resins with esters of carbamic acids are described and claimed in mycopending application Serial No. 707,043 filed October 31, 1946, of which the present application is a division. The aforesaid application Serial No. 707,043 has now been abandoned in favor of my copending application Serial No. 246,883, filed September 15, 1951 as a continuation-in-part of said application Serial No. 707.043.

Acrylamide, its homologues, its substitution products, and the alkylidene-bis derivatives thereof may be used in the practice of the present invention. Suitable compounds of this type include acrylamide, methacrylamide, ethacrylamide, methylene-bis-acrylamide, methylene-bismethacrylamide, ethylidene-bis-acrylamide, propylidene-bis-ethacrylamide, etc. The bis derivatives just mentioned are new chemical compounds and may be prepared by condensing a saturated lower aliphatic aldehyde with acrylamide, one of its homologues or one of its mono-N-substituted derivatives in a 1:2 molar proportion in the presence of strong acid as described and claimed in the copending application of Lennart A. Lundberg, Serial No. 707,040 filed October 31, 1946 now Patent No. 2,475,846 dated July 12, 1949. Moreover, monoand di-N- substituted acrylamides such as N-methyl acrylamide, N,N-dimethyl acrylamide, N-ethyl methacrylamide, N-methylol acrylamide, N-phenyl acrylamide, N,N-ditolyl methacrylamide, N-benzyl methacrylamide, N,N- dlbenzyl acrylamide, etc., may also be used in the compositions of the present invention as well as mixed substitution products, for example, N- methyl-N-benzyl acrylamide, N-phenyl-N-benzyl ethacrylamide, N-ethyl-N-tolyl acrylamide, etc.

The term an acrylamide as used in the present specification is intended to include acrylamide itself, its homologues such as methacrylamide, ethacrylamide, etc., and its substitution products hydric alcohol.

6' including N-alkyl acrylamides, N-acyl acrylamides, and N -alkaryl acrylamides.

Reactive resins suitable for polymerization with reactive materials containing the CH2=C group in accordance with the teachings of my invention are those which contain a plurality of alpha,beta-enals groups. 7 The simplest members of this group are those produced by the esterification of an alpha,beta-unsaturated organic acid with a polyhydric alcohol.

The preferred polyhydric alcohols are those which contain only primary hydroxyl groups since the presence of secondary hydroxyl groups may make it difiicult to obtain rapid esterification. The glycols are generally preferable. If colorless resins be desired or if optimum electrical properties be desired, it is preferable to use glycols which do not have any oxygen bridges in their structure, since the presence of oxygen linkages may lead to the formation of color bodies during the preparation of the resin. By the use of glycols which do not contain the oxygen bridges, clear colorless resins may be produced.

On the other hand, oxygen bridges may be desirable if the resin is to be used in coating as they cause films to dry faster.

The particular choice of glycol or other polyhydric alcohol used in preparing the resin is governed mainly by the desired physical properties of the intermediate and final polymerization products, especially hardness, impact resistance, distensibility, refractive index, adhesion, compatibility relationships, etc., including also solvent, water, alkali, acid, or chemical resistance in general.

The alpha,beta-unsaturated organic acids which I prefer to use in preparing the reactive resins include maleic, furmaric, itaconic, and citraconic, although other similar acids could be substituted such as mesaconic acid, aconitic acid, and halogenated maleie acids, such as chlormaleic acid, and any of the foregoing could be substituted in part by acrylic, beta benzoyl acrylic, methacrylic, Al-cyelohexene carboxylic, cinnamic, and crotonic acids. Obviously, various mixtures of these acids can be used where expedient.

The reactive resins may be modified with other substances which are used in alkyd resins, i. e., monohydric alcohols, monobasic acids, or dibasic acids, e. g., phthalic acid, succinic acid, glutaric acid, adipic acid, azelaic acid, sebacic acid, etc., which do not contain groups polymerizably rea'c-= tive with respect to organic substances containing CH2=C groups. The modifying agents are usually used as diluents or plasticizers, chemically combined in the resin. The use of a small proportion of the saturated dibasic acids generally improves the mechanical properties of the resins after copolymerization with the material containing the CH2=C group.

The reactive resins may be prepared from polyhydric alcohols other than the glycols or from mixtures including a glycol and a higher poly- Examples of these are glycerol, pentaerythritol, etc. Polyhydric alcohols containing more than two hydroxyl groups react very readily with the alpha,beta-unsaturated organic acids. Consequently, it may be preferable to use some monohydric alcohol in conjunction with the alcohols which contain more than two hydroxyl groups or else some monobasic acid may be used.

It is also possible to introduce initially into the resin structure a certain number of groupings of.

g; the type CH2=C through the use of unsatu- 1 rated alkylicornpounds'.

hol and methallyl alcohol;

While the reactive resins maybe alcohol in the reactive mixture and at least 25% polybasic acid in said reactive mixture.

37 monohydric alcohol or a dibasicacid which does not'contain polymerizably active groups withrespect to organic substances containing the CH2=C groups be used, theproportion'of such 'substancefwill depend on the properties required 1 of the polymerized reactive material-reactive resin mixture. 1Bytheuse of a relatively large proportion of a p'olymeriza'bly activedibasic acid,

' .e.g., maleic, in 'the reactive resin, a hard, tough polymer is produced upon subsequent reaction of said reactive resin with a reactive material conta-ining the CH2:C group. On the other hand,

if the reactive resin is obtained from a relatively small proportion of-polymerizably active dibasic' acid and a relatively large proportion of acidsv which do not contain groups polymerizably 'active with respectto organic substances contain- 1 ing CHz= 'C groups, asofter and more'rubbery cordance with my invention are preferably those having'a'n acid number not greater than 50, although in some cases resins having an acid number as high aslOD may be desirable. Generally the acid number should be a low as possible, but this is-sometimes controlled by practical considerations of operation such as time, tempera- 3 'ture, and economy.

a 1 The resins should be so formulated that the carboxyl groups of the acids are reacted with thetheoretical molar equivalent of the hydroxyl'v Y groups of the alcohols. In this connection it is to benoted that'thehydroxyl grcupsiof rhodifyj ingal c'ohols as wellias the carboxyl groups of modifying acids should beinoluded with the hydroxyl groups and carboxyl groups of the principal reactants, the polyhydric alcohol and th alpha,beta-'unsaturated ,polycarboxylic acid, re-

" x V 7 y r 55 reacted with dicarboxylic spectivelyh When glycols are acids it is preferable that the glycol be present in .a memratio to the'acid of not less than 1:2

and that:the molar ratio of monohydric alcohol to dicarboxylic acid be not greater, than 1:1.

One way of accomplish? ing this, for example, is by direct esterification of an unsaturated alcohol containing a 'CH2,=C. group. Examples of such alcohols are .allyl alcoo modified in the samegeneral manner astother alkyd resins, it is preferable to have at least 20% polyhydric masses dric alcohol to polycarboxylic acid should not exceedl mole of monohydric alcohol'for each carboxylic group of the polycarboXylic-acid in excess of 1. Thus, for example, a resin maybe prepared by the reaction of 1 mole ofvdipen-T taerythritol'with 5 moles of; 'furnari-c acid and 4 moleso'f monohydric alcohol. i

If" it is desirable tointroducelower alkyl groups into the resin, this-maybe done-by using maleic esters of monohydric alcohols, e. -g., ethyl maleate.

The: alkyl ester will then be-united with the resin by polymerization. This could not be accomplished with the saturated type of allgyd, e.'- g., phthalic acid esters of polyh-ydrlc alcohols;

Resins which contain a plurality of alpha-beta:

enal groups are sensitive to light, heat, and polymerizing catalysts. Since oxygen tends toca-usethese resins *to polymerize, it is desirable that the'resinsshould be made in in the absence of this substance, especially when colorless resins are required. 'The exclusion of oxygen and -poly-' merizing catalysts is desirable during the orepa ration of the resin and thepresence of dissolved oxygen in the original reactants is alsopreferably avoided. Moreover, dust and extraneous particles that reagents may "pick up usually 7 should be removed, especially if colorless resins are desired. One manner in which the dissolved latter instance, it maybe made to perform the oxide or other inert gas would be. partic' gases and other extraneous impurities may be" removed is throughthe-distillation'ofthe ingredients into the reaction chamber in the absence 7 Of all. r Y r In-order to keep'oxygen from contact with the reactants, an inert gas such ascarbon dioxide ornitrogen may be introduced intothe'reaction chamber.

the gas throughthe liquid reactants. In "the added function of agitating the mixture, thus eliminating the necessity for mechanical agitation. The inert gas will also carry away at least part of the water formed, and toward the end of the reaction it can be usedto :carry. away the reactants still remaining unreacted. Upon"sep aration of the Water :vapor the used carbon disuitable for making high grade colorless re ns since any residual reactive impurities such as oxygen would have beenremoved :in its passage through the first batch oi resin reactants,

In most cases ithasbeen found that a molar ratio of monohydricalcohol to dicarboxylic acid oflzfi produces. the best results (5.5 moles of glycol. being employedinthis case). The same generalrules apply whenpolyhydric alcohols Tether than .glycols such as pentaerythritol, di-' pentaerythritol or polyallyl alcohols are -used,flor when other polycarboxylic acids having more than 'two carboxylic groups are used. In other wordsgthe ratio of the monohydric alcohol to the polycarboxylic acid shouldpreferably be not greater .than 1:.1 althoughhigher ratios ofmonohydric alcoholmay be employed if desired. How- The effect of light "is not so important ij the reactants a e pu fi nd he reac i carried on in an inert atmosphere, as outlined above; However, as an; added precaution the esterifica-Q tion maybe conducted in the dark. It is also advisable to avoid local overheating, andidiscol oration is minimized if the reaction is conducted b low {a te e a e f b u 200. C- L'Io avoid overheatingit is advisable to raise the .temperature slowly at the beginning especially if' an anhydride be used since the reaction .betweenan anhydrideand an alcohol is exothermic; The followingreactive resins areamone thQSe' which may be used according to the process of the present invention with thepolyrnerizablyf reactive. amide ,compoundsffethylene glycol tumarate, diethylene glycol fumarate, alpha 7o. Propylene glycol maleate, polyethylenexglycol ma ates, e. a. hex t y ene lyco ma e polymethylene glycol'maleates .(e. g., :decamethylene'glycol maleate), octadecandiol fumarate,

themalcic. esters of 2 ;2-.dimethyl "propanediole-ilfi,

y evgnior optimum results theratio of m9130hglyccrohmaleate undecylenate, 'tr-iethylenegly ol This may be done either by merely passing the gas over the surface or by bubbling chlormaleate, triethylene glycol terpene maleate (derived from the interaction of /2 mole of terpene and 1 mole of maleic in the presence of an excess of terpene) Many different modified alkyd resins may be employed. Such modified resins include all of those previously mentioned and generally described as modified with a monohydric alcohol or with a monocarboxylic acid or with both a monohydric alcohol and a monocarboxylic acid. Among the alcohols which may be used are n-butanol, 1,2 and 1,3-dichloropropanols (HO-CI-Iz-CHCl-CHeCl and CH2C1CHOCH2C1), the amyl alcohols, cyclohexanol, n-hexanol, 2-methyl hexanol, n-octanol, decanol, dodecanol, tetradecanol, cetyl alcohol, octadecanol, reduced geraniol, reduced fatty oils such as coconut oil, palm oil, etc., benzyl alcohol, phenylethyl alcohol, furfuryl alcohol, tetrahydrofurfuryl alcohol, and various ether alcohols such as and those sold under the trade name of Cellosolve and Carbitol, such as butyl Cellosolve (the monobutyl ether of ethylene glycol), butyl Carbitol (the monobutyl ether of diethylene glycol), etc. alcohols may be reacted with glycidol and the reaction products thereof employed as a glycol in the preparation of the unsaturated alkyd resins. Of the cycloaliphatic alcohols, those derived by reaction of dienes with unsaturated aldehydes followed by reduction such as isohexyl cyclohexyl carbinol which is obtained by reducing thereaction product of beta myrcenewith acrolein, are especially suitable. Various acids and other compounds having esterifiable hydroxyl groups may be employed in the modification of the unsaturated alkyd resins to be used in accordance with my invention for copolymerization with allyl compounds. Thus, for example, the hydroxy acids may be employed, including lactic acid, alpha-hydroxydecanoic acid, omega-hydroxymyristic acid, etc. Other substances containing hydroxyl groups which may be used are, for example, ethylene cyanohydrin. Still other alcohols which may be employed are terpineol, fenchyl alcohol, and the unsaturated alcohols ineluding allyl alcohol, methallyl alcohol, oleyl alcohol, linoleyl alcohol. I have found that copolymers of alkyd resins modified with monohydric alcohol give especially high temperature resistance when employed as a bond to laminate glass cloth or when glass fibers are used as a filler in castings or moldings.

It is preferable that primary alcohols be used as modifiers for the unsaturated alkyd resins, and it is also preferable that such alcohols have boiling points above about 200 C. If low boiling alcohols, e. g., tetrahydrofurfuryl alcohol, be used, it is preferable that the resin be prepared azeotropically as described below.

Since the viscosity of the resin frequently becomes quite high if the esterification is carried to a low acid number, it may be desirable to produce the resin under azeotropic conditions. Accordingly, the esterification is conducted in an organic solvent which dissolves the reactants as well as the resultant resin and which is preferably'substantially insoluble in'water. Examples of these are: benzene, toluene, xylene, chloroform, carbon tetrachloride, ethylene dichloride,

Furthermore, various m-onohydric 10 propylene dichloride, ethylene and propylene trichlorides, butylene dichloride and trichloride, and also higher boiling solvents such as cresol and methyl cyclohexanone although some of these may tend to darken the resin. The mixture is refluxed in such a manner as to separate the water formed by the esterification. Much' lower temperatures are used than are used under the conditions outlined in the examples. Suitable temperatures range between -145 (7., for example, for the boiling members of the group of solvents set forth above. Obviously, this will vary with different solvents and with different concentrations of solvent. The range of preferred concentrations for the inert solvent is from about 25% to about 50%. An es-terification catalyst is usually necessary because comparatively low temperature is employed. Examples of these are thymol sulfonic acid, d-campho'r sulfonic acid, naphthalene sulfonic acid, and p-tolu'ene sulfonic acid. Obviously, other known esterificati-on catalysts could be used. A resin having any particular acid number, if made azeotropically, will usually have a lower viscosity than one of the corresponding acid number not made azeotropically.

Monocarboxylic acids which are saturated may be employed as modifiers for the unsaturated monocarboxylic acids heretofore mentioned. Such acids include acetic acid, caproic acid, lauric acid, stearic acid, etc. Any of the monocarboxylic acids which are available in the form of the anhydride may be used as the anhydride instead of as the acid.

The polymerization catalysts include the organic superoxides, aldehydic and acidic peroxides. Among the preferred catalysts there are: the acidic peroxides, e. g., benzoyl peroxide, phthalic peroxide, succinic peroxide, and benzoyl acetic peroxide; fatty oil acid peroxides, e. g., coconut oil 'acid'peroxides, lauric peroxide, stearicperoxide, and oleic peroxide; alcohol peroxides, e. g., tertiary butyl hydroperoxide usually called tertiary butyl peroxide, and terpene oxides, e. g., ascaridole. Still other polymerization catalysts might be used in some instances such as soluble cobalt salts (particularly the linoleate and naphthenate) p-toluene sulfonic acid, aluminum chloride, stannic chloride, and boron trifiuoride.

The term polymerization catalyst as used in this specification is not intended to cover oxygen contained in the resin as an impurity. While this small amount of oxygen would only catalyze the reaction to a very small extent, in order to eliminate any ambiguity the term polymerization catalyst is specifically defined as excluding any oxygen present as an impurity in the resin itself.

The concentration of catalyst employed is usually small, i. e., for the preferred catalysts from about 1 part catalyst per 1000 parts of the reactive mixture to about 2 parts per parts of the reactive mixture. If an inhibitor be present, up to 5% or even more of catalyst may be necessary according to the concentration of inhibitor. Where fillers are used which contain high concentrations of substances which act as inhibitors, e. g., wood flour, the concentration of catalyst necessary to effect polymerization may be well above 5%.

Oneo'f the difficulties in the use of the compositions described above is thatthey are not susceptible to storage in the mixed form because polymerization will usually take place even at room temperature within a comparatively short 'p iyhyidric phenols, and aromatic" amines;

' cificgexamples of this groupof'iinhibitors are j 7 inhibitors;-

aotiver unncarriedi out.

5 V time; Moreoveriwhen it isidesired; tojou'mv the icompositionsavery' rapidlyunderheat andf pressure; the reaction becomes Lat-f times so; vi orous f ithati'itrcannotrbecontrolled; :In oriier'tov over- 1 .comeithsepdifficulties, it has been found. adviszablesto incorporateaa-smallproportionof a'poly: rmei'ifiation'finhibitor injthe mixture. oflresin and smas es 'neactiyeimaterial. Whenlitisdesiredto-use this Qfitlie inhihitorzas. well-as: to promote. the :poly:

hern ation. JBy careiuli control of the .concen.-'

tit iaitirins" 01fv inhibitor and. catalystya uniform inrmiuchwith .a .Tgood' :reacti-onvelocity is obtain- :abiss; Upomsubiection of: this. mixture to; poly:

:merization: conditions, such :as. heat, light, or a ..nfixturansmall;percentageofthepolymerization 1 V .catalystisnddedisufiioientto overcome the efi'ect -(29mDilatation;of. both, :with or: without pressure, I

Ianiniusible, insolubleresin,isprocluced whichhas re desirable characteristics than. the

dr by the. polymerization of mix.-

resins? 1 5 ttssnaitmammgne polymerizationinhibitor ,such 3:3, fQI'i'115138iI10BQ17h6lackofifractlnfe.-

finitable;polymerization. inhibitors for this 'reaction are phenolic compounds, especially 1 the aspen.

esinsreactiveanaterialeombinationlfither rafter; bodyingl or: it maybe addedito esterification 0f;th.e.,saicl reactive resin. ".By1adq be incorporated in the re;

k tees; higher. tempera:- tures than; thosepniention'ed above can be :used.

Since the-timeof curingiis desirably muchishorter in pressure molding, and since the reactive material tcontainingfthe 'CHQ;C group would the'refor'e'not be lost. spa-easily; a higher tempera ture is preferreil.v

. The particular-reactive:resin,l'reactiweinaterial,

. and catalyst combination: is selectedaccordingito the type of: product idesired, taking: into account the. solubilities' ofrthe reactants as. well {as the character oft-he; resulting: gels. Some ic'ombina tions of reactive resins'andreactive materials" result in opaque gels while others give clear prod-. ucts in the-gel state; Gbviously, for many pur posesan opaqne gel maybe used equally as-we-ll asiacleargel.

Ifthe unsaturated; alkyd resin be incompatible with the 'ie'active-" amido material; chemical in:-

teraction of the type: described :cannotlfcocur.

Under these conditions, a. solventmay 'beintrmcluced as an additional constituent; If the sol:- vent is inert, itplays no-part in-thereaction but is so selectedthatboththe'reactive material and r the resin are soluble, yielding a homogeneous system; of reactive material, inert solvent "and resin. This invention relates: to compatiblecomibinationsof a reactive 'resinand areactivematerial. containing a; C'Hz;C. group. Suclr combinations may he: obtained by: the use of: inert blendingsolvents where necessa ily although the use of only reactive materials. containing; the

.CH2:C groupwhich: act as. solvents is pre- 1 ferredl:

inal; reactive? resin before .or during: the

nsitlieizinhibitorbefore] the esterificatiomit is sometimes.- possihle to use: an inhibitor which" 'won ii' addin .ht inhibitor to: the. unesterifiedmixti'ire,

tiiieiinhihitor'maybeeome; bound into theE- resin 4113911 subsequent;'esterification. The; olymerizable compositions of the present .inventionmay be polymerizedi in the presence .0; heat or lightzor a combination of both. Ultra-j violetrli htis:moreeffiectivel than ordinary light.

suitable' in most instances since substantial amounts; or: theeiieactive material will be lost by evaporation before the 1 reaction between the resin andrea'ctive material is complete; Accords nglyi i temperature betweenroom temperature,

' .aboutize jezsr Gama the boilingpoint' is usually employed :wherhia j polymerization of this nature The rate of. polymerization doublesifonabout each 10216;) rise in tempera- .tureiitttfthis reaction. A temperature is selected whiclizfwill give aEsuitabIe reaction rate and yet not cause substantial volatilizationi f Obviously, it will be necessary to use lower temperaturesif .largeorvery-thiok piecesarabeingcastbecause ofithe 'exothermioity of thezreactionrancl the poor heat. conductivity of the reaction: mixture;

Where-suitable; precautionsare; taken; to. pre- 7 vent. evaporation; of; my reactive materialt'or The terms- "compatible?" and: homogeneous as; usedina thesneeiiicationl and claims are intended to indicate a; system; the constituents of which are uniformly distnibuted'throughout the whole mass. and. tihen' applied. to solutions, to indicate that they: maybe; either, true solutions or colloidal solutions. as long as tliey aresube' stantiallystable.v

When a reactive-resinand a reactive-material containing the H2.;C? gnoupundergoohemical optimum temperaturei of: conversion: depends somewhatonthe boiling pointtof the-reactive material and. on the pressures used? For ex? 1 ample;;at:.atmosphericpressure as in coating and castingioperations;artemperature near orabove the-boiling? point. of the: reactive material sun reaction, certainpossibiiities arise. The reactive resiniand reactive material; may combine-in such a. manner as to lead' tov the formation of. a" resinouscolloidal; entity, and'- theend-product is. clear, glass-like, and homogeneous.

tively; the reactive resin and the reactive materialmay interactin-such amanner as to yield colloidal entities. wherein; varying degrees of opacity or colloidal colorsresult'. Theend-rprorlnot under these conditions may be partially translucent or opaque; V V

The finalresin composition is obtained reacting a resin containing the: alpha betasenal .t=' groups with a; reactive; material containing: the The chemical: reaction which is' beiievedi'to. take place is. a combination of the reactivematerial' withthea-resin at the points" of unsaturation, yielding a lessunsaturatedl system which is essentially: insoluble and: infusible. Or-

dinarily when airesini's dissolvedin asolvent, the

changeswhichoccur areiphysicalin nature. The

. resin/may be isolatedfrom the solvent mixture chemically unchanged} In: the presentinventi'on, however, the combinationof they reactive material containingtheCH2=G group and the reactive resinfbecoma an inseparable entity, the original ingredients not: being capable of being removedby so-lventsrfor theoriginal ingredients.

Through the us'eof-jasmall amount ofreactiye where pressurelmolding? Alternar alkyd resin in conjunction with a large amount of reactive material containing the CH2=C group, the final composition contains not only the ester groupings which were originally present in the alkyd resin, but also the carbon-tocarbon molecular bonds which link the reactive material and the reactive resin. Through the use of a small amount of resin and a large amount of reactive material, the composite resin is no longer soluble in those inert solvents wherein the reactive material resinifled alone would dissolve. Under long exposure to the inert solvent the composite resin Will tend to imbibe a certain quantity of inert solvent, but it does not possess the solubility of the reactive material when resinified alone. This property is a distinct advantage in that the physical contour of an object made of the polymerized resin is not lost through solution.

Comparison of the softening point of the re active material containing the CH2=C group alone and of the softening point of the composite resin formed through interaction of the resin and reactive material shows that the softening point of the latter has been raised. The softening point may be increased very markedly depending upon the ratio of resin used in the composition.

In general the softening point of resins has a distinct bearing on their behavior at room tem- P perature as well as at elevated temperatures. Where the softening point is too low, difliculty is encountered in that articles made from the resin slowly lose their shape. In large articles, the effect becomes very noticeable. point when too high, on the other hand, results in a composition which will not soften sufficiently in a mold. Roughly, three types of compositions exist with respect to the ratio of resin to reactive material containing the CH2=C group. First, a large amount of reactive material and a small amount of resin; second, substantial quantities of both ingredients; third, a large amount of resin and a small amount of reactive material. The second composition when fully cured possesses no softening point. The first and third varieties of composition when cured may, under high temperatures and pressure, be made to flow slightly.

The composition obtained from substantial quantities of both reactive material containing the CH2:C group and reactive resin in the cured state may be machined, turned on a lathe, sanded, and polished, and used in general as a turnery composition. The absence of softening renders the material particularly adaptable to this purpose. In that it is'unflowable, it may be machined without danger of softening and gumming tools. Moreover, such a composition may, if desired, be obtained in large blocks.

My resins may be utilized in: moldings, with or without filler; laminated materials as the bonding agent; adhesives; coating compositions for use in finishes for wood, metals, or plastics, or in the treatment of fibrous materials such as papencloth, or leather; as impregnating agents for fibrous materials; as assistants in dyeing, etc.

In order to use the composition for moldings,

it may be necessary to prevent the composition from curing too fast. During the change to a hard resin, varying stages of hardness exist and by interrupting the reaction at a definite point, the material may then be placed in a form and hardened under heat. Sheets of resin may be A softening twisted or made to conform to a pattern and then. subsequently cured in the shaped form by heatalone.

One manner in which this may be accomplished is to polymerize the reactive resin and reactive material containing the CH2:C group without catalysts until the material is completely cured. By grinding this partially polymerized material, which can then be shaped under heat and pressure.

To produce moldings or laminated materials, combinations of reactive resin and reactive material containing the CH2=C group may be: mixed with one or more of the various fillers, e. g.,. wood flour, wood fiber, paper dust, clay, diatomaceous earths, zein, glass wool, mica, granite dust, silk flock, cotton flock, steel wool, silicon carbide, paper, cloth of any fiber including glass, sand, silica flour, white, black or colored pigments, etc. Such mixtures may be partially polymerized, ground, and molded. On the other hand, the composition may be. bodied and introduced directly into a mold and polymerization to a solid resin conducted in one step.

The composition of reactive resin and reactive material may be used for impregnating various porous objects or it may be employed as a coating composition.

If the polymerizable compositions are to be molded under low pressure (e. g. 0-50 lbs/sq. in.) the composition may be employed without bodying or partial polymerization.

The polymerizable mixture may be introduced in a positive mold without any filler. In this instance, however, the reaction becomes quite exothermic but this may be conveniently controlled by the addition of a suitable polymerization inhibitor.

The ratio of reactive material containing the CH2:C group to reactive resin in the final composition will not only have a bearing on the softening point and on methods of working the resin, but on various other physical properties, e. g., light transmission, scratch resistance, indentation hardness, and arc resistance. By a judicious selection of the ratio of reactive material to reactive resin a composition best suited to these varying needs of industry may be fabricated.

, The methods by which the reactive material containing the CH2:C group may be made to combine are various. Heat, light, or catalysts may be used or combinations of these, or a combination of heat and pressure. Any suitable method of heating may be used including the application of high frequency electric fields to induce heat in the reactive mixture to polymerize the latter.

During the transformation. to a hard massive structure, various stages occur which may be roughly separated as follows: first, the induction period wherein the material remains as a sol which slowly increases in viscosity; secondly, the transformation of the sol into a gel; and third, the hardening of the gel. During the transformation of the sol to a gel, an exothermic reaction occurs which maybe very violent if uncontrolled. Moreover, the gel has relatively poor heat conductivity resulting in poor transfer not only of external heat but of the heat that is generated during chemical reaction throughout the mass. Cognizance has to be taken of these features in the hardening of the composition,

a molding composition is obtained 17 resins is quick curing time which renders them available for injection molding, blow molding, and extrusion molding.

Similar advantages are present in coating operations such as the lack of shrinkage of the film due to loss of solvent because of the combination between the'reactive resin and the reactive material containing the CH2=C group. Furthermore, the composition dries from the bottom, there are no bubbles from the solvent, and there is no water driven 01f. A clear, bubblefree, impervious coating is therefore more readily obtainable with the combinations of a reactive resin and reactive material containing the CH2:C' group than with other coating compositions. Since there is nosolvent to be removed and since air is not needed todry the compositions, relatively thick layers may be applied in one operation.

I claim:

1. As a new product, a resinous interpolymer obtained by polymerization of a plurality of copolymerizable materials comprising a polymerizable unsaturated alkyd resin containing a plurality of polymerizably reactive alpha,betaenal groups and a compatible monomeric copolymerizable substance selected from the group consisting of compounds having the following general formulae:

in which Y is a member of the group consisting of hydrogen and alkyl radicals of 1 to 2 carbon atoms, R1 is selected from the group consisting of hydrogen and alkyl, alkylol, aryl, and aralkyl radicals, R2 is selected from the group consisting of alkyl, alkylol, aryl and aralkyl radicals, R3 is selected from the group consisting of hydrogen and alkyl, aryl and aralkyl radicals, and X is an alkylidene radical.

2. A product produced by interpolymerizinga mixture including a polymerizable unsaturated alkyd resin containing a plurality of polymerizand ably reactive alpha,beta-enal groups and methyland in which Y is a number of the group consisting of hydrogen and alkyl radicals of 1 to 2 carbon atoms, R1 is selected from the group consisting of hydrogen and alkyl, alkylol, aryl, and aralkyl radicals, R2 is selected from the group consisting of alkyl, alkylol, aryl and aralkyl radicals, R3 is selected from the group consisting of hydrogen and alkyl, aryl and aralkyl radicals, and X is an alkylidene radical, and a catalyst for accelerating the copolymerization of said unsaturated alkyd resin with said substance compatible therewith, and (2) polymerizing said polymerizable composition.

5. A polymerizable composition comprising a polymerizable unsaturated alkyd resin containing a plurality of polymerizably reactive alpha,- beta-enal groups and a compatible monomeric polymerizable substance selected from the group consisting of compounds having the following general formulae:

in which Y is a member of the group consisting of hydrogen and alkyl radicals of 1 to 2 carbon atoms, R1 is selected from the group consisting of hydrogen and alkyl, alkylol, aryl, and aralkyl radicals, R2 is selected from the group consisting of alkyl, alkylol, aryl and aralkyl radicals, R3 is selected from the group consisting of hydrogen and alkyl, aryl and aralkyl radicals, and X is an alkylidene radical.

6. A polymerizable composition comprising a and polymerizable unsaturated alkyd resin containing a plurality of polymerizably reactive alpha,- beta-enal groups and methylene bis-acrylamide.

7. A polymerizable composition comprising a polymerizable unsaturated alkyd resin containing a plurality of polymerizably reactive alpha,betaenal groups and N-butyl acrylamide.

8. A polymerizable composition according to claim 5 which contains a, catalyst for accelerating the copolymerization of said unsaturated alkyd resin with said polymerizable substance compatible therewith.

9. A polymerizable composition comprising an unsaturated alkyd resin obtained by reaction of ingredients comprising ethylene glycol, fumaric acid and sebacic acid, and methylene bis-acrylamide.

10. A polymerizable composition comprising an unsaturated alkyd resin obtained by reaction of ingredients comprising ethylene glycol, fumaric acid and sebacic acid, and methylene bis-methacrylamide.

11. A molding composition comprising (1) a filler, (2) a polymerizable unsaturated alkyd resin containing a plurality of polymerizably reactive alpha,beta-enal groups, (3) a compatible monomeric polymerizable substance selected from the group consisting of compounds having the following general formulae:

and

* qii hyro i ande ky V 1 atom; R41 klelec esigf o z .lfogep a d' kylralkyloll an li andarallsyl t i d sel s t d mm thei rqiin-oons stine 'oi-aligyL a k lokeryl nd ar kylmd palsgfis s Se1Qc -d' m he roup onsisti g of hydro n.

ison al kylidene radical.

e ro p 'cons etin and-alk an-y and ara ad cals. "and. is; an

dica s of 1 t0. 2 carbon V whi h ia m mber: o ymei roupqqonsistiil V 2Q o V 1Q.f.,:h drogen and. alkylrradioals of '1' to 2% carbon iwms, R1 isgselected ,irom the group. consisting A sh peda'rticle O prising ag ll V copolymer obtained by interpolymerizing d-pQIY- mevizazhlgcomnqs -tiqn co prisin ianun atumted v a kyd resin-contain g a p ural ty of, polymqr r -l e ct warlphah ta-enal rq psjand'al omatible: monqmen e no.1 n e able ub tanc se- 1 e. ;t 1 :imm h s roup consistin ofqomponnds" having h i gwin eneralioitmula r Y Y eggand.

iifiiiiiq x 14511 2 q e qi twi t n magi r ri'd @1 5 rad als p n-2 5 59;? e

of hydrogen and alkyl, allgylollaryl, and;

radicals, R2 is selected from the group cohsisting.

oi alkyl, 311151101, arYlrandaralkyl. radidalsi-Ra is selected f;rom thez'groiipiconsisting of hydrogen and alkyl, anylwand ara lkykradioals, and x is an alky-lideneradioal, V

14, A laminated rartiol'e'comprisingr a ,plumlity of-sh'eetS of; fibrous rmaiteria lbonded;together with an inte rpolymer of a; mixture including (1 a apolymerizable unsaturated alkyd. resin containi- 1 'ing a, plurality of polymerizabl'y -reaotive;a1pha;;-

-l:geta-ena,1' groups, ands-('2) a. compatible monoemer ic polymerizable substanoeselected iromfthe groupconsistingof-oompounds having therfollowa mg general "formulae: r

in which Y-is a, "member-of the group consisting oi -hydrogen -and-a1k y 1 radicals of; -1 togzparbon atoms; R1 is selected from the group-oonsi'sltih'g of hydrogen and- IkyI, alkylol, a-ryl, and aralkyl radica1s,rR,z is seleotedirom the group consisting of alkyl, alkylol, owl and aralkyl radicals, R3 is selected from the group consisting of hydrogen and a1ky1,-a,r y1 and aralkyl radicals, and X e alpha..-

j is an alkylidene radical.

EDWARD L. KROPA.

V 4 REFEBENGISSCITEDJ h P QWinQL re er tfi-lei 0i.- @imt; V

- UNITED YS'IAFIESLPA'I'ENTS;

1 re o moo in the 

1. AS A NEW PRODUCT, A RESINOUS INTERPOLYMER OBTAINED BY POLYMERIZATION OF A PLURALITY OF COPOLYMERIZABLE MATERIALS COMPRISING A POLYMERIZABLE UNSATURATED ALKYD RESIN CONTAINING A PLURALITY OF POLYMERIZABLY REACTIVE ALPHA, BETAENAL GROUPS AND A COMPATIBLE MONOMERIC COPOLYMERIZABLE SUBSTANCE SELECTED FROM THE GROUP CONSISTING OF COMPOUNDS HAVING THE FOLLOWING GENERAL FORMULAE: 